Method and apparatus for continuously manufacturing metal sheets

ABSTRACT

The present invention relates to a method and an apparatus for continuously manufacturing metal sheets. The method includes: (a) providing a first metal coil having a first end and a second end; (b) continuously driving the first end of the first metal coil to move forward; (c) providing a second metal coil having a first end and a second end; and (d) lapping and rolling the first end of the second metal coil and the second end of the first metal coil, so that the second metal coil moves forward following the first metal coil. In this way, the present invention only causes a few seconds&#39; delay in rolling, so a small piler is needed, thus reducing the space of the production line and saving the facility cost.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method and an apparatus for continuously manufacturing metal sheets, and more particularly to a method and an apparatus for continuously manufacturing metal sheets by rolling.

2. Description of the Related Art

FIG. 1 shows a schematic view of a conventional apparatus for continuously manufacturing metal sheets. The conventional continuously manufacturing apparatus 1 includes an unwinder 11, a welding device 12, a piler 13, a main processing device 14, and a winder 15. The unwinder 11 is used for unwinding a metal coil 16 (for example, a steel coil). The main processing device 14 is used for processing the metal coil 16 passing through it, and the processing method is cold rolling, acid pickling, annealing, zinc-plating, balking varnish, finishing, tempering, leveling, punching, or roll forming. The winder 15 is used for continuously winding the metal coil 16 passing through the main processing device 14.

When the unwinder 11 finishes unwinding the metal coil 16, as the main processing device 14 and the winder 15 must keep running, another metal coil 16 should be fitted onto the unwinder 11 and its front end must be joined to the rear end of the previous metal coil 16, in order not to interrupt the production line. In the conventional continuously manufacturing apparatus 1, the two metal coils 16 are joined as follows: the ends of the two metal coils 16 are first abutted, and then welded together by the welding device 12.

It takes about 20-30 seconds for the welding device 12 to weld the ends of the two metal coils 16. During welding, the main processing device 14 and the winder 15 still keep running, so the piler 13 is needed for piling articles. The piler 13 includes a plurality of rollers 131. The rollers 131 are capable of moving upward and downward, so as to adjust the total length of the metal coil 16 in the piler 13, thus achieving the purpose of article piling.

The conventional continuously manufacturing apparatus 1 has the following defects. First the alignment of the two ends of the two metal coils 16 needs to be highly accurate. That is, the ends of the two metal coils 16 must be perfectly aligned with each other in order not to affect the subsequent process, and this results in an increase of the manufacturing cost. Secondly, after welding, a protruding welding seam 161 is left at the ends of the two metal coils 16, as shown in FIG. 2, and thus a device for leveling the welding seam 161 must be added. Thirdly, the piler 13 is not only expensive, but also occupies a large space.

Therefore, an innovative and advanced method and apparatus for continuously manufacturing metal sheets are needed to solve the above problems.

SUMMARY OF THE INVENTION

The present invention is mainly directed to a method for continuously manufacturing metal sheets, which includes the following steps: (a) providing a first metal coil having a first end and a second end; (b) continuously driving the first end of the first metal coil to move forward; (c) providing a second metal coil having a first end and a second end; and (d) lapping and rolling the first end of the second metal coil and the second end of the first metal coil, so that the second metal coil moves forward following the first metal coil.

The present invention is further directed to an apparatus for continuously manufacturing metal sheets which includes a first unwinder, a second unwinder, a rolling device, and a conveyor device. The first unwinder is used for unwinding a first metal coil. The second unwinder is used for unwinding a second metal coil. The rolling device is used for rolling one end of the first metal coil and one end of the second metal coil. The conveyor device is used for continuously driving the first metal coil and the second metal coil joined to the first metal coil.

The first end of the second metal coil overlaps the second end of the first metal coil, so the alignment does not need to be highly accurate as in the conventional continuously manufacturing apparatus. Moreover, as the upper and lower surfaces of the rolled portion are even, the device for leveling the welding seam as in the conventional continuously manufacturing apparatus is unnecessary. Further, the present invention only makes a delay of less than 3 seconds in rolling, so a small piler is needed, thus reducing the space of the production line and saving the facility cost.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a conventional apparatus for continuously manufacturing metal sheets;

FIG. 2 is a schematic view of a welding seam left after welding according to a conventional joining manner;

FIG. 3 is a schematic view of an apparatus for continuously manufacturing metal sheets according to the present invention;

FIG. 4 is a schematic view of a rolling device in the apparatus for continuously manufacturing metal sheets according to the present invention;

FIG. 5 shows a rolled portion after rolling according to a joining manner of the present invention; and

FIG. 6 is a flow chart of a method for continuously manufacturing metal sheets according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 3 shows a schematic view of an apparatus for continuously manufacturing metal sheets according to the present invention. The continuously manufacturing apparatus 3 includes a first unwinder 31, a second unwinder 32, a preprocessing device 33, a rolling device 34, a post-processing device 35, a main processing device 36, a conveyor device (for example, a plurality of pulleys 41), and a winder 37. The first unwinder 31 is used for unwinding a first metal coil 38. The first metal coil 38 has a first end (front end) and a second end 381 (rear end). The unwound first metal coil 38 is a flat sheet, and is driven by the conveyor device to enter the main processing device 36. The main processing device 36 is used for processing the first metal coil 38 passing through it, and the processing method is cold rolling, acid pickling, annealing, zinc-plating, baking varnish, finishing, tempering, leveling, punching, or roll forming.

Afterward, the first metal coil 38 passing through the main processing device 36 is wound by the winder 37 or directly reprocessed (for example, by punching shear). In this embodiment, the first end of the first metal coil 38 is wound by the winder 37.

The second unwinder 32 is used for unwinding a second metal coil 39. The second metal coil 39 has a first end (front end) 391 and a second end (rear end). The unwound second metal coil 39 is a flat sheet, and is driven by the conveyor device. The second metal coil 39 and the first metal coil 38 may be of the same material or of different materials. When the first unwinder 31 finishes unwinding the first metal coil 38, as the main processing device 36 and the winder 37 must keep running, the second metal coil 39 should be fitted onto the second unwinder 32 to be unwound and the first end 391 of the second metal coil 39 must be joined to the second end 381 of the first metal coil 38, in order not to interrupt the production line.

The preprocessing device 33 is used for preprocessing the first end 391 of the second metal coil 39 and the second end 381 of the first metal coil 38. In this embodiment, the preprocessing device 33 includes a surface treatment device (not shown), for treating surfaces to be joined. The surfaces to be joined include a lower surface of the first end 391 of the second metal coil 39 and an upper surface of the second end 381 of the first metal coil 38. The method of surface treatment is selected from among mechanical polishing, mechanical sand-blasting, stamping, and plasma spraying, or combinations thereof. Surface treatment is employed to remove an oxide layer or oil film on the surfaces to be joined, so as to expose the metal substances on the lower surface of the first end 391 of the second metal coil 39 and the upper surface of the second end 381 of the first metal coil 38, thereby achieving an effect of joining by rolling. For example, if the materials of the second metal coil 39 and the first metal coil 38 are both steel, mechanical polishing and mechanical sand-blasting are adopted in sequence. If the material of the second metal coil 39 or the first metal coil 38 is aluminum, only mechanical polishing is adopted, and mechanical sand-blasting is unnecessary.

In other applications, the preprocessing device 33 further includes a heating device (not shown), for heating the first end 391 of the second metal coil 39 and the second end 381 of the first metal coil 38.

FIG. 4 shows a schematic view of a rolling device in the apparatus for continuously manufacturing metal sheets according to the present invention. The rolling device 34 is used for rolling the second end 381 of the first metal coil 38 and the first end 391 of the second metal coil 39. In this embodiment, the rolling device 34 includes two rollers 341. When the first end 391 of the second metal coil 39 overlaps the second end 381 of the first metal coil 38, the rollers 341 contact and roll the first end 391 of the second metal coil 39 and the second end 381 of the first metal coil 38, so as to form a rolled portion 40 (FIG. 5).

Again referring to FIG. 3, the post-processing device 35 is used for post-processing the rolled portion 40 between the first end 391 of the second metal coil 39 and the second end 381 of the first metal coil 38. In this embodiment the post-processing device 35 includes at trimming device (not shown), for trimming off protruding portions at both sides of the rolled portion 40. In other applications, the post-processing device 35 includes a marking device (not shown), for forming a mark on the rolled portion 40.

Afterward, the conveyor device continuously drives the first metal coil 38 and the second metal coil 39 joined to the first metal coil 38 to enter the main processing device 36. Then, the main processing device 36 processes the second metal coil 39 passing through it. Again, the processing method is cold rolling, acid pickling, annealing, zinc-plating, baking varnish, finishing, tempering, leveling, punching, or roll forming.

Afterward, the second metal coil 39 passing through the main processing device 36 is wound by the winder 37 or directly reprocessed (for example, by punching shear). In this embodiment, the second metal coil 39 is continuously wound by the winder 37 after the first metal coil 38.

It is understood that when the second unwinder 32 finishes unwinding the second metal coil 39, if necessary, another metal coil is fitted onto the first unwinder 31 to be unwound and the front end of the metal coil must be joined to the second end of the second metal coil 39, in order not to interrupt the production line.

The present invention has the following advantages. Firstly, the first end 391 of the second metal coil 39 overlaps the second end 381 of the first metal coil 38, so the alignment does not need to be highly accurate as in the conventional continuously manufacturing apparatus 1. Secondly, as the upper and lower surfaces of the rolled portion 40 are even, the device for leveling the welding seam 161 as in the conventional continuously manufacturing apparatus 1 is unnecessary. Thirdly, the present invention only causes a delay of less than 3 seconds in rolling, so a small piler is needed, thus reducing the space of the production line and saving the facility cost.

FIG. 6 shows a flow chart of a method for continuously manufacturing metal sheets according to the present invention. Referring to FIG. 3, the method for continuously manufacturing metal sheets according to the present invention includes the following steps. In Step S601, a first metal coil 38 having a first end and a second end 381 is provided. In Step S602, the first metal coil 38 is mainly processed by cold rolling, acid pickling, annealing, zinc-plating, baking varnish, finishing, tempering, leveling, punching, or roll forming. In Step S603, the first end of the first metal coil 38 is continuously driven to move forward, so that the first end of the first metal coil 38 is continuously wound or the first metal coil 38 is directly reprocessed (for example, by punching shear). In this embodiment, the first end of the first metal coil 38 is continuously wound by the winder 37.

In Step S604, a second metal coil 39 having a first end 391 and a second end is provided.

In Step S605, the surfaces to be joined at the first end 391 of the second metal coil 39 and the second end 381 of the first metal coil 38 are preprocessed. The surfaces to be joined include the lower surface of the first end 391 of the second metal coil 39 and the upper surface of the second end 381 of the first metal coil 38. In this embodiment, the method of surface treatment is selected from among mechanical polishing, mechanical sand-blasting, stamping, and plasma spraying, or combinations thereof. Surface treatment is employed to remove an oxide layer or oil film on the surfaces to be joined, so as to expose the metal substances on the lower surface of the first end 391 of the second metal coil 39 and the upper surface of the second end 381 of the first metal coil 38, thereby enhancing the joining effect. For example, if the materials of the second metal coil 39 and the first metal coil 38 are both steel, mechanical polishing and mechanical sand-blasting are adopted in sequence. If the material of the second metal coil 39 or the first metal coil 38 is aluminum, only mechanical polishing is adopted, and mechanical sand-blasting is unnecessary. In other applications, the preprocessing step is heating, so as to heat up the first end 391 of the second metal coil 39 and the second end 381 of the first metal coil 38.

In Step S606, the first end 391 of the second metal coil 39 and the second end 381 of the first metal coil 38 overlap each other and are rolled to form a rolled portion 40, so that the second metal coil 39 moves forward following the first metal coil 38.

In Step S607, the rolled portion 40 between the first end 391 of the second metal coil 39 and the second end 381 of the first metal coil 38 is post-processed. In this embodiment, the post-processing step is trimming off protruding portions at both sides of the rolled portion 40. In other applications, the post-processing step is forming a mark on the rolled portion 40.

In Step S608, the second metal coil 39 is mainly processed. After the first metal coil 38 is mainly processed, the second metal coil 39 joined to the first metal coil 38 is then mainly processed. Again, the processing method is cold rolling, acid pickling, annealing, zinc-plating, baking varnish, finishing, tempering, leveling, punching, or roll forming.

Afterward, the second metal coil 39 is wound or directly reprocessed (for example, by punching shear) In this embodiment, the second metal coil 39 is continuously wound after the first metal coil 38. It is understood that, when the second metal coil 39 is completely unwound, if necessary, another metal coil is unwound and the front end of the metal coil must be joined to the second end of the second metal coil 39, in order not to interrupt the production line.

While several embodiments of the present invention have been illustrated and described, various modifications and improvements can be made by those skilled in the art. The embodiments of the present invention are therefore described in an illustrative but not restrictive sense. It is intended that the present invention should not be limited to the particular forms as illustrated, and that all modifications which maintain the spirit and scope of the present invention are within the scope defined in the appended claims. 

1. A method for continuously manufacturing metal sheets, comprising: (a) providing a first metal coil having a first end and a second end; (b) continuously driving the first end of the first metal coil to move forward; (c) providing a second metal coil having a first end and a second end; (d) lapping and rolling the first end of the second metal coil and the second end of the first metal coil, so that the second metal coil moves forward following the first metal coil.
 2. The continuously manufacturing method as claimed in claim 1, further comprising a step of mainly processing the first metal coil after Step (a).
 3. The continuously manufacturing method as claimed in claim 2, wherein the mainly processing method is selected from among cold rolling, acid pickling, annealing, zinc-plating, baking varnish, finishing, tempering, leveling, punching, and roll forming.
 4. The continuously manufacturing method as claimed in claim 1, further comprising a step of preprocessing the first end of the second metal coil and the second end of the first metal coil after Step (c).
 5. The continuously manufacturing method as claimed in claim 4, wherein the preprocessing step comprises surface treatment, so as to expose the metal substances at the first end of the second metal coil and the second end of the first metal coil.
 6. The continuously manufacturing method as claimed in claim 5, wherein the method of surface treatment is selected from among mechanical polishing, mechanical sand-blasting, stamping, and plasma spraying.
 7. The continuously manufacturing method as claimed in claim 4, wherein the preprocessing step comprises heating, so as to heat up the first end of the second metal coil and the second end of the first metal coil.
 8. The continuously manufacturing method as claimed in claim 1, further comprising a step of post-processing a rolled portion between the first end of the second metal coil and the second end of the first metal coil after Step (d).
 9. The continuously manufacturing method as claimed in claim 8, wherein the post-processing step comprises trimming off protruding portions at both sides of the rolled portion.
 10. The continuously manufacturing method as claimed in claim 8, wherein the post-processing step comprises forming a mark on the rolled portion.
 11. The continuously manufacturing method as claimed in claim 1, further comprising a step of mainly processing the second metal coil after Step (d).
 12. The continuously manufacturing method as claimed in claim 11, wherein the mainly processing method is selected from among cold rolling, acid pickling, annealing, zinc-plating, baking varnish, finishing, tempering, leveling, punching, and roll forming.
 13. An apparatus for continuously manufacturing metal sheets, comprising: a first unwinder, for unwinding a first metal coil; a second unwinder, for unwinding a second metal coil; a rolling device, for rolling one end of the first metal coil and one end of the second metal coil; and a conveyor device, for continuously driving the first metal coil and the second metal coil joined to the first metal coil.
 14. The continuously manufacturing apparatus as claimed in claim 13, further comprising a main processing device, for processing metal coils passing through it.
 15. The continuously manufacturing method as claimed in claim 14, wherein the processing method of the main processing device is selected from among cold rolling, acid pickling, annealing, zinc-plating, baking varnish, finishing, tempering, leveling, punching, and roll forming.
 16. The continuously manufacturing apparatus as claimed in claim 13, further comprising a preprocessing device, for preprocessing the end of the second metal coil and the end of the first metal coil.
 17. The continuously manufacturing apparatus as claimed in claim 16, wherein the preprocessing device comprises a surface treatment device, for exposing the metal substances at the end of the second metal coil and the end of the first metal coil.
 18. The continuously manufacturing apparatus as claimed in claim 16, wherein the preprocessing device comprises a heating device, for heating up the end of the second metal coil and the end of the first metal coil.
 19. The continuously manufacturing apparatus as claimed in claim 13, further comprising a post-processing device, for post-processing a rolled portion between the end of the second metal coil and the end of the first metal coil.
 20. The continuously manufacturing apparatus as claimed in claim 19, wherein the post-processing device comprises a trimming device, for trimming off protruding portions at both sides of the rolled portion.
 21. The continuously manufacturing apparatus as claimed in claim 19, wherein the post-processing device comprises a marking device, for forming a mark on the rolled portion.
 22. The continuously manufacturing apparatus as claimed in claim 13, wherein the first metal coil and the second metal coil are of the same material.
 23. The continuously manufacturing apparatus as claimed in claim 13, wherein the first metal coil and the second metal coil are of different materials.
 24. The continuously manufacturing apparatus as claimed in claim 13, wherein the rolling device comprises two rollers, for contacting the end of the first metal coil and the end of the second metal coil.
 25. The continuously manufacturing apparatus as claimed in claim 13, further comprising a winder, for continuously winding the first metal coil and the second metal coil joined to the first metal coil. 